US6746533B2 - Quick drying plaster - Google Patents
Quick drying plaster Download PDFInfo
- Publication number
- US6746533B2 US6746533B2 US10/158,225 US15822502A US6746533B2 US 6746533 B2 US6746533 B2 US 6746533B2 US 15822502 A US15822502 A US 15822502A US 6746533 B2 US6746533 B2 US 6746533B2
- Authority
- US
- United States
- Prior art keywords
- plaster
- fatty alcohol
- gypsum
- weight
- sulfate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/16—Sulfur-containing compounds
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
Definitions
- plaster be as light as possible, while maintaining strength and other desirable properties and characteristics.
- Use of plaster products having reduced density makes those products easier to work with and transport, for example.
- One way of reducing the density of dry plaster is to introduce foam into the aqueous gypsum slurry from which the plaster is formed.
- foam formers such as guar gum, bentonite, polyvinyl alcohol, or latex polymers.
- the rate at which set gypsum can be dried to form dry plaster is commercially important. Thus, it is desirable to achieve a rapid drying rate. Drying set gypsum at elevated temperature is effective in increasing drying rate as compared with drying at ambient temperature. Hence, kilns, ovens, and other devices are used to dry set gypsum to form plaster products. However, overdrying, which causes loss of strength, is more prevalent when heated drying is used. Thus, care must be taken to ensure that no portion of the set gypsum is overdried. The above-described prior art products exhibit standard drying rates and are susceptible to overdrying.
- the invention is directed to a gypsum-containing mixture, to quick-drying plaster made therefrom, and to a method for increasing the drying rate of plaster.
- the plaster dries more quickly by including fatty alcohol sulfate in the slurry from which the plaster is made.
- the invention is directed to a method for increasing the drying rate of plaster and to the plaster thus made. Resulting plaster of the invention can be quickly and efficiently dried, yet retains desirable properties and characteristics, such as compressive strength and fire resistance. Plaster of the invention is particularly suited for forming castings and as fireproofing, such as is found in safes and fire-resistant containers.
- the invention also is directed to a gypsum-containing mixture which, when mixed with an appropriate quantity of water, forms an aqueous slurry that can be quickly dried to form dry plaster.
- gypsum calcium sulfate hemihydrate, which is sometimes called stucco, becomes hydrated in water to form an aqueous slurry of calcium sulfate dihydrate.
- the slurry hardens, or sets, to form a solid identified herein as set plaster. Any remaining excess water then is removed by drying, with or without heating, to form dry plaster.
- quick-drying plaster of the invention can be made lightweight, yet exhibit better compressive strength, and dry more quickly, than known foamed plaster, by adding polyvinyl alcohol to the slurry.
- the drying rate of plaster is increased by including alcohol sulfate in the slurry from which the plaster is made.
- alcohol sulfate for example, gypsum and alcohol sulfate can be combined with water to hydrate to gypsum and form an aqueous slurry, which may also contain other compounds.
- the slurry is hardened.
- the hardened slurry dries quickly to form dry plaster without adversely affecting the gypsum crystal.
- the plaster may be made lightweight by including polyvinyl alcohol in the slurry.
- Gypsum or calcium sulfate hemihydrate, is available commercially under many names including inter alia molding plaster, statuary plaster, plaster, plaster of paris, and gypsum stucco. Either ⁇ -plaster or ⁇ -plaster may be used in the method of the invention. Skilled practitioners recognize that “synthetic” gypsum is recovered from certain flue gas desulfurization operations and differs from naturally-occurring gypsum because it has a different, typically round, particle shape.
- Such materials may be added to the aqueous slurry or to the mixture of the invention in quantities that do not adversely affect the basic nature of the invention. Skilled practitioners recognize that some types, such as molding plaster and ⁇ -plaster, will dry more quickly than other types, because the initial water demand is lower.
- Alcohol sulfate suitable for use in the mixture of the invention has an alkyl moiety having between about 8 and about 20 carbon atoms.
- the alcohol sulfate has an alkyl moiety of between about 10 and about 16 carbon atoms.
- Such alcohol sulfate is commercially available.
- One product line of suitable alcohol sulfates is available from Witco under the trade names Supralate® and Kunol®. These products are fatty alcohol sulfates, typically combined with sodium as the balancing ionic moiety.
- the fatty alcohol sulfates described herein are solids.
- the mixture of the invention will be a dry mixture, and alcohol sulfate will be introduced into the slurry in this way. Dry mixtures are particularly advantageous, as they can be easily transported and stored.
- fatty alcohol sulfates are available in liquid form, whether alone or as, for example, an aqueous solution or suspension. Such liquid products are not suitably incorporated to dry mixtures.
- the mixture of the invention can be formed with such liquid phase alcohol sulfate by combining gypsum with the alcohol sulfate and water to form a slurry. Introduction of the alcohol sulfate directly into the slurry is within the scope of the claimed invention.
- Any suitable method can be used to determine pouring consistency. For example, one can determine the pat diameter obtained when gypsum is hydrated with a given quantity of water. Comparison of such diameters for divers gypsum sources will provide a relative measure of fluidity for the sources.
- Dry plaster of the invention is made by drying set gypsum to remove excess water.
- the set product can be dried under ambient conditions or by heating in a kiln, oven, or other suitable device known to skilled practitioners.
- drying temperatures between about 125 and about 225° F. are utilized for a time sufficient to achieve the desired degree of dryness at the drying temperature selected.
- drying set plaster to a pre-selected moisture level may take about 225 minutes at 150° F., but only 60 minutes at 200° F. With the guidance provided herein, a skilled practitioner will be able to select suitable drying conditions.
- Plaster of the invention can be dried in any manner known to skilled practitioners. Plaster of the invention will dry more quickly at a given temperature than known plasters without suffering adverse effects of overdrying at the edges and thin portions. As skilled practitioners recognize, overdrying causes disruption of the dihydrate gypsum crystal and dehydration thereof to calcium sulfate hemihydrate, which has a very low compressive strength.
- the inventors also have discovered that including polyvinyl alcohol in the slurry can form particularly lightweight plaster.
- the polyvinyl alcohol foams the plaster sufficiently to reduce the density thereof
- the resultant product dries quickly and has particularly high compressive strength.
- the compressive strength is about 25% higher than plaster foamed to the same density by known methods, preferably about 40% higher, and more preferably about 50% higher.
- Polyvinyl alcohol having any degree of hydrolysis, typically at least about 75%, is suitably used in the invention.
- Polyvinyl alcohol is available as aqueous solutions in varying concentrations and as solid.
- solid polyvinyl alcohol can be added to a dry mix to form a dry mixture, and liquid polyvinyl alcohol solution can be introduced as part of formation of the slurry.
- polyvinyl alcohol having a degree of hydrolysis less than about 88% is freely soluble in water at about 150° F.
- solubility of polyvinyl alcohol decreases with increasing degree of hydrolysis, so higher temperatures are required for complete dissolution.
- a degree of hydrolysis of less than about 88% is preferred.
- Gypsum A molding plaster (Georgia-Pacific Gypsum)
- Gypsum B continuous stucco (Georgia-Pacific Gypsum)
- Gypsum C plaster containing vermiculite (fire-resistant-available from Georgia-Pacific Gypsum)
- Gypsum D synthetic stucco (Wheatfield)
- the pouring consistency (PC) of Gypsum C with 0.1% Lomar D dispersant was determined at 56 grams of water per 100 grams of gypsum, and sufficient dispersant was added to Gypsums A (0.2%), B (0.4%), and D (0.3%) to match the PC of Gypsum C.
- Gypsum D was prepared with and without sodium citrate retarder.
- the gypsum was fully hydrated, and two-inch cubes of each plaster were weighed before being put into an oven maintained at 150° F. The weight of each cube was determined periodically for 225 minutes. Gypsum D, without retarder, dried most quickly and completely, as can be seen in the following Table 1.
- drying rate decreased after about 180 minutes for the samples dried at 150° F., and after about 105 minutes for the samples dried at 200° F., showing evidence of a reduction in the amount of free moisture remaining in the sample.
- Gypsum (U.S. Gypsum), identified herein as ‘E’, was prepared by hydrating 100 grams of gypsum with 56 grams of water.
- One-inch cubes of A, C, D, and E were dried at 200° F.
- the porosity was determined by a displacement method.
- the specific surface area was determined by Laser Diffraction Analysis. Both are reported in Table 4 below. As can be seen, the lower the specific surface area, the quicker the drying time even though the porosity of the quickest drying gypsum was lowest of all gypsums. Because of the vermiculite in gypsum C, the relationship between specific surface area and porosity is not the same as it is for the other gypsums.
Abstract
Description
TABLE 1 | ||
Gypsum |
A | B | C | D | D/retarder |
Drying Time, minutes | Wt Percent Lost |
0 | 0 | 0 | 0 | 0 | 0 |
30 | 3.4 | 3.2 | 3.4 | 4.2 | 3.4 |
60 | 6.6 | 6.2 | 6.6 | 8.0 | 6.4 |
90 | 9.9 | 9.4 | 10.1 | 11.6 | 10.0 |
120 | 13.6 | 12.5 | 14.2 | 14.9 | 13.5 |
150 | 17.9 | 15.4 | 17.9 | 18.7 | 15.4 |
180 | 19.6 | 18.2 | 19.6 | 20.1 | 18.2 |
195 | 20.5 | 19.2 | 20.8 | 21.6 | 19.0 |
210 | 21.5 | 20.1 | 21.6 | 22.3 | 19.9 |
225 | 22.3 | 21.0 | 22.5 | 23.0 | 20.5 |
TABLE 2 | |||
Gypsum |
A | B | C | D |
Drying Time, minutes | Wt Percent Lost | |
0 | 0 | 0 | 0 | 0 |
30 | 4.5 | 5.3 | 5.1 | 5.7 |
60 | 10.1 | 10.2 | 11.0 | 11.3 |
90 | 15.0 | 14.9 | 15.5 | 15.9 |
105 | 17.4 | 17.4 | 18.0 | 18.1 |
120 | 19.5 | 19.5 | 20.1 | 19.5 |
135 | 20.8 | 20.8 | 21.7 | 20.8 |
150 | 22.3 | 21.7 | 22.8 | 21.7 |
165 | 23.0 | 23.0 | 24.0 | 22.4 |
180 | 23.3 | 23.4 | 24.5 | 23.4 |
195 | 24.0 | 24.0 | 24.9 | 23.8 |
TABLE 3 | |||
Gypsum |
A | C | D | E |
Drying Time, minutes | Wt Percent Lost | |
0 | 0 | 0 | 0 | 0 |
15 | 7.2 | 8.1 | 8.1 | 8.1 |
30 | 15.0 | 15.0 | 15.3 | 14.0 |
45 | 19.0 | 19.9 | 19.0 | 18.0 |
60 | 22.5 | 23.7 | 22.5 | 20.9 |
75 | 23.9 | 24.9 | 23.9 | 22.3 |
90 | 24.0 | 25.0 | 24.0 | 23.0 |
105 | 24.1 | 25.1 | 24.1 | 23.2 |
TABLE 4 | ||
Gypsum | Porosity, % | Specific Surface Area, cm2/cm3 |
A | 28.8 | 7004 |
C | 25.9 | 5103 |
D | 24.9 | 7390 |
E | 22.6 | 3255 |
Gypsum |
3A | 3B | 3C | 3D | 3E | 3F | ||
Dupanol, wt % | 0.009 | 0.0125 | 0.0125 | 0.025 | 0.05 | 0.10 |
Foamaster PD#1, wt. % | 0.05 | |||||
Lomar D, wt. % | 0.05 | 0.2 | 0.2 | |||
TABLE 5 | ||
Gypsum |
3A | 3B | 3C | 3D | 3E | 3F | 3G |
Drying Time, min | Wt Percent Lost |
0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
15 | 8.4 | 6.8 | 7.6 | 6.8 | 7.6 | 8.8 | 6.8 |
30 | 15.6 | 13.0 | 14.3 | 14.3 | 14.7 | 16.7 | 14.7 |
45 | 21.4 | 19.7 | 19.7 | 19.7 | 19.7 | 20.7 | 19.7 |
60 | 22.8 | 22.1 | 22.2 | 22.2 | 22.2 | 22.2 | 22.2 |
75 | 23.9 | 23.3 | 23.3 | 23.3 | 23.3 | 23.3 | 23.3 |
90 | 24.0 | 23.8 | 23.8 | 23.8 | 23.8 | 23.8 | 23.8 |
105 | 24.2 | 24.0 | 24.0 | 24.0 | 24.0 | 24.0 | 24.0 |
TABLE 6 | ||
Gypsum |
Comparative | 4A | 4B | ||
Gypsum | 100 | 100 | 100 |
Polyvinyl alcohol | 0.625 | 0.625 | |
Sodium lauryl sulfate (Dupanol) ® | 0.05 | 0.025 | |
TABLE 7 | ||
Gypsum |
Est'd. Foamed | |||||
Comparative | Comparative | 4A | 4B | ||
Density, lb/ft3 | 47 | 75 | 44 | 50 |
Comp. Strength, psi | 450 | 2810 | 695 | 905 |
Claims (20)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/158,225 US6746533B2 (en) | 2002-05-31 | 2002-05-31 | Quick drying plaster |
MXPA03004860A MXPA03004860A (en) | 2002-05-31 | 2003-05-30 | Quick drying plaster. |
CA002430670A CA2430670A1 (en) | 2002-05-31 | 2003-05-30 | Quick drying plaster |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/158,225 US6746533B2 (en) | 2002-05-31 | 2002-05-31 | Quick drying plaster |
Publications (2)
Publication Number | Publication Date |
---|---|
US20030221591A1 US20030221591A1 (en) | 2003-12-04 |
US6746533B2 true US6746533B2 (en) | 2004-06-08 |
Family
ID=29582619
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/158,225 Expired - Lifetime US6746533B2 (en) | 2002-05-31 | 2002-05-31 | Quick drying plaster |
Country Status (3)
Country | Link |
---|---|
US (1) | US6746533B2 (en) |
CA (1) | CA2430670A1 (en) |
MX (1) | MXPA03004860A (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB0712259D0 (en) * | 2007-06-22 | 2007-08-01 | Houghton Mark P | Drying aid for plaster |
Citations (21)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3015626A (en) | 1959-09-29 | 1962-01-02 | John C Kingsbury | Insulating composition |
US3203813A (en) | 1962-06-18 | 1965-08-31 | United Clay Mines Corp | Thermal insulating material, composition and process for making the same |
US3793042A (en) | 1970-12-24 | 1974-02-19 | Combustion Eng | Insulating monolithic refractory |
US3989534A (en) | 1973-03-19 | 1976-11-02 | Mark Plunguian | Foamed cementitious compositions and method of producing same |
US4000241A (en) | 1975-06-13 | 1976-12-28 | Dunn Daniel K | Insulation method and materials |
US4129447A (en) * | 1976-02-17 | 1978-12-12 | Wacker-Chemie Gmbh | Process for the preparation of hydrophobic agents |
US4159302A (en) | 1975-10-14 | 1979-06-26 | Georgia-Pacific Corporation | Fire door core |
US4161855A (en) | 1976-04-21 | 1979-07-24 | General Electric Company | Thermal insulation material and process for making the same |
US4298394A (en) * | 1978-07-26 | 1981-11-03 | Bpb Industries Limited | Organic gypsum set accelerators |
US4336068A (en) | 1978-07-03 | 1982-06-22 | Lebanon Steel Foundry | High strength insulation materials |
US4351867A (en) * | 1981-03-26 | 1982-09-28 | General Electric Co. | Thermal insulation composite of cellular cementitious material |
US4518652A (en) | 1983-07-15 | 1985-05-21 | United States Gypsum Company | Method for forming a lightweight cementitious structural product and product formed thereby |
US4911759A (en) * | 1986-03-12 | 1990-03-27 | G-C Dental Industiral Corporation | Dental gypsum compositions in low-dusting powdery form |
US5098943A (en) * | 1989-02-22 | 1992-03-24 | Mitsubishi Kasei Corporation | Water repellent and water repellent gypsum composition |
US5256222A (en) | 1990-09-10 | 1993-10-26 | Manville Corporation | Lightweight building material board |
US5294256A (en) * | 1989-06-27 | 1994-03-15 | W. R. Grace & Co.-Conn. | Additives for hydraulic cement compositions |
US5298070A (en) * | 1990-11-09 | 1994-03-29 | Shell Oil Company | Cement fluid loss reduction |
US5340392A (en) * | 1991-04-26 | 1994-08-23 | Franklin Industries, Inc. | Method and product of calcium sulfate dihydrate as filler in aqueous polymer dispersions |
US5505771A (en) * | 1991-07-17 | 1996-04-09 | Mitsubishi Chemical Corporation | Dental gypsum composition |
US5723226A (en) | 1995-06-07 | 1998-03-03 | G-P Gypsum Corporation | Gypsum-containing compositions and fire-resistant articles |
US6171388B1 (en) * | 1998-03-17 | 2001-01-09 | Rhodia Inc. | Lightweight gypsum composition |
-
2002
- 2002-05-31 US US10/158,225 patent/US6746533B2/en not_active Expired - Lifetime
-
2003
- 2003-05-30 CA CA002430670A patent/CA2430670A1/en not_active Abandoned
- 2003-05-30 MX MXPA03004860A patent/MXPA03004860A/en active IP Right Grant
Patent Citations (21)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3015626A (en) | 1959-09-29 | 1962-01-02 | John C Kingsbury | Insulating composition |
US3203813A (en) | 1962-06-18 | 1965-08-31 | United Clay Mines Corp | Thermal insulating material, composition and process for making the same |
US3793042A (en) | 1970-12-24 | 1974-02-19 | Combustion Eng | Insulating monolithic refractory |
US3989534A (en) | 1973-03-19 | 1976-11-02 | Mark Plunguian | Foamed cementitious compositions and method of producing same |
US4000241A (en) | 1975-06-13 | 1976-12-28 | Dunn Daniel K | Insulation method and materials |
US4159302A (en) | 1975-10-14 | 1979-06-26 | Georgia-Pacific Corporation | Fire door core |
US4129447A (en) * | 1976-02-17 | 1978-12-12 | Wacker-Chemie Gmbh | Process for the preparation of hydrophobic agents |
US4161855A (en) | 1976-04-21 | 1979-07-24 | General Electric Company | Thermal insulation material and process for making the same |
US4336068A (en) | 1978-07-03 | 1982-06-22 | Lebanon Steel Foundry | High strength insulation materials |
US4298394A (en) * | 1978-07-26 | 1981-11-03 | Bpb Industries Limited | Organic gypsum set accelerators |
US4351867A (en) * | 1981-03-26 | 1982-09-28 | General Electric Co. | Thermal insulation composite of cellular cementitious material |
US4518652A (en) | 1983-07-15 | 1985-05-21 | United States Gypsum Company | Method for forming a lightweight cementitious structural product and product formed thereby |
US4911759A (en) * | 1986-03-12 | 1990-03-27 | G-C Dental Industiral Corporation | Dental gypsum compositions in low-dusting powdery form |
US5098943A (en) * | 1989-02-22 | 1992-03-24 | Mitsubishi Kasei Corporation | Water repellent and water repellent gypsum composition |
US5294256A (en) * | 1989-06-27 | 1994-03-15 | W. R. Grace & Co.-Conn. | Additives for hydraulic cement compositions |
US5256222A (en) | 1990-09-10 | 1993-10-26 | Manville Corporation | Lightweight building material board |
US5298070A (en) * | 1990-11-09 | 1994-03-29 | Shell Oil Company | Cement fluid loss reduction |
US5340392A (en) * | 1991-04-26 | 1994-08-23 | Franklin Industries, Inc. | Method and product of calcium sulfate dihydrate as filler in aqueous polymer dispersions |
US5505771A (en) * | 1991-07-17 | 1996-04-09 | Mitsubishi Chemical Corporation | Dental gypsum composition |
US5723226A (en) | 1995-06-07 | 1998-03-03 | G-P Gypsum Corporation | Gypsum-containing compositions and fire-resistant articles |
US6171388B1 (en) * | 1998-03-17 | 2001-01-09 | Rhodia Inc. | Lightweight gypsum composition |
Also Published As
Publication number | Publication date |
---|---|
US20030221591A1 (en) | 2003-12-04 |
CA2430670A1 (en) | 2003-11-30 |
MXPA03004860A (en) | 2005-02-14 |
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AS | Assignment |
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